Diseño de un sistema de pistolas Dumming para un sistema Jig de la línea de producción Shineray X30, para la empresa Ciudad Del Auto Ciauto Cia.Ltda basado en un análisis de factibilidad

Abstract

This project was carried out at Ciudad del Auto CIAUTO CÍA. LTDA., specifically on the Shineray X30 body production line, where it was identified that the spot welding process at the side panel and floor assembly station was performed manually, resulting in operational limitations related to non-productive time, restricted accessibility to the work area, operator overexertion, and elevated cycle times within the station. In order to optimize this process, a semi-automated system of self-actuated Dummy welding guns was designed and implemented, integrated into the existing production JIG while considering the geometric, structural, pneumatic, electrical, and quality requirements demanded by the automotive industry. The applied methodology combined field, bibliographic, and experimental methods, allowing the analysis of the station’s real operational behavior, the development of tower-type support structures for the precise positioning of the welding guns, and the technical validation of the system under actual operating conditions. The implementation significantly reduced direct operator intervention in hard-to-access areas, particularly on the underside of the vehicle body, while also reducing the process cycle time from 16 minutes and 23 seconds to 2 minutes and 26 seconds, maintaining a 100% acceptance rate of the weld spots according to the criteria established by the AWS D8.1M/D8.1 standard and the company’s internal quality requirements. Furthermore, the results demonstrated operational savings of approximately 111.96 man-hours per month, enabling the redistribution of human resources to higher-demand production lines without increasing operational workload. From a production perspective, the daily manufacturing capacity increased from an average of 12 to 14 units, representing an approximate 16.67% increase in productivity while maintaining the same number of operators. Finally, the technical-economic analysis determined that the proposed system is both operationally viable and financially feasible, since the improvements in productivity, reduction of non-productive times, and optimization of human resources contribute to a progressive return on investment throughout the estimated service life of the implemented system.